engine CHEVROLET EXPRESS CARGO VAN 2003 1.G Manual PDF

How to Inspect the Engine Air
Cleaner/Filter
To inspect the air cleaner/®lter, remove the ®lter from
the vehicle and lightly shake ®lter to release loose dust
and dirt. If the ®lter remains caked with dirt, a new
®lter is required.
To remove and reinstall the ®lter and reset the indicator
(if equipped), do the following:
The engine air cleaner/®lter is located near the center of
the engine compartment.
1. Unhook the retainer clips and remove the cover.2. Lift the ®lter out of the engine air cleaner/®lter
housing. Care should be taken to dislodge as
little dirt as possible.
3. Clean the engine air cleaner/®lter housing.
4. Install the new engine air cleaner/®lter into the
engine air cleaner/®lter housing. Make sure that
it ®ts properly into the housing.
5. Reinstall the cover and fasten the retaining clips.
{CAUTION:
Operating the engine with the air cleaner/®lter
off can cause you or others to be burned. The
air cleaner not only cleans the air, it helps to
stop ¯ame if the engine back®res. If it isn't
there and the engine back®res, you could
be burned. Don't drive with it off, and be
careful working on the engine with the air
cleaner/®lter off.
Notice:If the air cleaner/®lter is off, a back®re can
cause a damaging engine ®re. And, dirt can
easily get into your engine, which will damage it.
Always have the air cleaner/®lter in place when
you're driving.
5-18

Automatic Transmission Fluid
When to Check and Change
A good time to check your automatic transmission ¯uid
level is when the engine oil is changed.
Change both the ¯uid and ®lter every 50,000 miles
(83,000 km) if the vehicle's GVWR is over 8,600 or if
the vehicle is mainly driven under one or more of these
conditions:
·In heavy city traffic where the outside temperature
regularly reaches 90ÉF (32ÉC) or higher.
·In hilly or mountainous terrain.
·When doing frequent trailer towing.
·Uses such as found in taxi, police or delivery
service.
If your vehicle's GVWR is not over 8,600 and you do
not use your vehicle under any of these conditions,
change the ¯uid and ®lter every 100,000 miles
(166 000 km).
See
Part A: Scheduled Maintenance Services on
page 6-4.
How to Check
Because this operation can be a little difficult, you may
choose to have this done at the dealership service
department.
If you do it yourself, be sure to follow all the instructions
here, or you could get a false reading on the dipstick.
Notice:Too much or too little ¯uid can damage
your transmission. Too much can mean that some
of the ¯uid could come out and fall on hot engine
part or exhaust system parts, starting a ®re.
Too little ¯uid could cause the transmission to
overheat. Be sure to get an accurate reading if you
check your transmission ¯uid.
Wait at least 30 minutes before checking the
transmission ¯uid level if you have been driving:
·When outside temperatures are above 90ÉF (32ÉC).
·At high speed for quite a while.
·In heavy traffic ± especially in hot weather.
·While pulling a trailer.
To get the right reading, the ¯uid should be at
normal operating temperature, which is 180ÉF to 200ÉF
(82ÉC to 93ÉC).
5-19

Get the vehicle warmed up by driving about 15 miles
(24 km) when outside temperatures are above 50ÉF
(10ÉC). If it's colder than 50ÉF (10ÉC), drive the vehicle
in DRIVE (D) until the engine temperature gage
moves and then remains steady for 10 minutes.
A cold ¯uid check can be made after the vehicle has
been sitting for eight hours or more with the engine off,
but this is used only as a reference. Let the engine
run at idle for ®ve minutes if outside temperatures are
50ÉF (10ÉC) or more. If it's colder than 50ÉF (10ÉC), you
may have to idle the engine longer. Should the ¯uid
level be low during this cold check, you
mustcheck the
¯uid hot before adding ¯uid. Checking the ¯uid hot
will give you a more accurate reading of the ¯uid level.
Checking the Fluid Level
Prepare your vehicle as follows:
·Park your vehicle on a level place. Keep the engine
running.
·With the parking brake applied, place the shift lever
in PARK (P).
·With your foot on the brake pedal, move the shift
lever through each gear range, pausing for about
three seconds in each range. Then, position the shift
lever in PARK (P).
·Let the engine run at idle for three minutes or more.
Then, without shutting off the engine, follow these steps:
The transmission dipstick
is located near the center
of the engine compartment
and will be labeled with
this graphic shown.
See
Engine Compartment Overview on page 5-12for
more information on location.
·Flip the handle up and then pull out the dipstick and
wipe it with a clean rag or paper towel.
·Push it back in all the way, wait three seconds and
then pull it back out again.
5-20

·Check both sides of the dipstick, and read the lower
level. The ¯uid level must be in the COLD area for
a cold check or in the HOT area or cross-hatched
area for a hot check.
·If the ¯uid level is in the acceptable range, push the
dipstick back in all the way; then ¯ip the handle
down to lock the dipstick in place.
How to Add Fluid
Refer to the Maintenance Schedule to determine what
kind of transmission ¯uid to use. SeePart D:
Recommended Fluids and Lubricants on page 6-18.
Using a funnel, add ¯uid down the transmission dipstick
tube only after checking the transmission ¯uid while it
is hot. (A cold check is used only as a reference.) If the
¯uid level is low, add only enough of the proper ¯uid
to bring the level up to the HOT area for a hot check.
It doesn't take much ¯uid, generally less than one pint
(0.5 L).
Don't over®ll.
Notice:We recommend you use only ¯uid labeled
DEXRONž-III, because ¯uid with that label is
made especially for your automatic transmission.
Damage caused by ¯uid other than DEXRON
ž-III is
not covered by your new vehicle warranty.
·After adding ¯uid, recheck the ¯uid level as
described under ªHow to Check.º
·When the correct ¯uid level is obtained, push the
dipstick back in all the way; then ¯ip the handle
down to lock the dipstick in place.
Engine Coolant
The cooling system in your vehicle is ®lled with
DEX-COOLžengine coolant. This coolant is designed
to remain in your vehicle for 5 years or 150,000 miles
(240 000 km), whichever occurs ®rst, if you add
only DEX-COOL
žextended life coolant.
The following explains your cooling system and how to
add coolant when it is low. If you have a problem
with engine overheating, see
Engine Overheating on
page 5-24.
5-21

A 50/50 mixture of clean, drinkable water and
DEX-COOLžcoolant will:
·Give freezing protection down to-34ÉF (-37ÉC).
·Give boiling protection up to 265ÉF (129ÉC).
·Protect against rust and corrosion.
·Help keep the proper engine temperature.
·Let the warning lights and gages work as
they should.
Notice:When adding coolant, it is important that
you use only DEX-COOLž(silicate-free) coolant.
If coolant other than DEX-COOLžis added to
the system, premature engine, heater core or
radiator corrosion may result. In addition, the engine
coolant will require change sooner -- at 30,000 miles
(50,000 km) or 24 months, whichever occurs ®rst.
Damage caused by the use of coolant other
than DEX-COOL
žis not covered by your new vehicle
warranty.
What to Use
Use a mixture of one-halfclean, drinkable waterand
one-half DEX-COOLžcoolant which won't damage
aluminum parts. If you use this coolant mixture,
you don't need to add anything else.
{CAUTION:
Adding only plain water to your cooling
system can be dangerous. Plain water, or
some other liquid such as alcohol, can boil
before the proper coolant mixture will. Your
vehicle's coolant warning system is set for the
proper coolant mixture. With plain water or the
wrong mixture, your engine could get too hot
but you wouldn't get the overheat warning.
Your engine could catch ®re and you or others
could be burned. Use a 50/50 mixture of clean,
drinkable water and the proper coolant.
Notice:If you use an improper coolant mixture,
your engine could overheat and be badly damaged.
The repair cost wouldn't be covered by your
warranty. Too much water in the mixture can freeze
and crack the engine, radiator, heater core and
other parts.
If you have to add coolant more than four times a year,
have your dealer check your cooling system.
Notice:If you use the proper coolant, you don't
have to add extra inhibitors or additives which claim
to improve the system. These can be harmful.
5-22

Checking Coolant
The coolant recovery tank
is located near the center
of the engine
compartment. See
Engine
Compartment Overview
on page 5-12
for more
information on location.
The vehicle must be on a level surface. When your
engine is cold, the coolant level should be at COLD
FILL, or a little higher.
Adding Coolant
If you need more coolant, add the proper DEX-COOLž
coolant mixtureat the coolant recovery tank.
{CAUTION:
Turning the radiator pressure cap when the
engine and radiator are hot can allow steam
and scalding liquids to blow out and burn
you badly. With the coolant recovery tank,
you will almost never have to add coolant at
the radiator. Never turn the radiator pressure
cap Ð even a little Ð when the engine and
radiator are hot.
Add coolant mixture at the recovery tank, but be careful
not to spill it.
{CAUTION:
You can be burned if you spill coolant on hot
engine parts. Coolant contains ethylene glycol,
and it will burn if the engine parts are hot
enough. Don't spill coolant on a hot engine.
Occasionally check the coolant level in the radiator. For
information on how to add coolant to the radiator,
see
Cooling System on page 5-26.
5-23

Radiator Pressure Cap
The radiator pressure cap is located near the center of
the engine compartment. SeeEngine Compartment
Overview on page 5-12for more information on location.
Notice:Your radiator cap is a pressure-type cap
and must be tightly installed to prevent coolant loss
and possible engine damage from overheating.
Engine Overheating
You will ®nd a coolant temperature gage on your
vehicle's instrument panel.
If Steam Is Coming From Your Engine
5-24

{CAUTION:
Steam from an overheated engine can burn
you badly, even if you just open the hood.
Stay away from the engine if you see or hear
steam coming from it. Just turn it off and get
everyone away from the vehicle until it cools
down. Wait until there is no sign of steam or
coolant before you open the hood.
If you keep driving when your engine is
overheated, the liquids in it can catch ®re. You
or others could be badly burned. Stop your
engine if it overheats, and get out of the
vehicle until the engine is cool.
See ªOverheated Engine Protection Operating
Modeº in the Index for information on driving
to a safe place in an emergency.
Notice:If your engine catches ®re because you
keep driving with no coolant, your vehicle can
be badly damaged. The costly repairs would
not be covered by your warranty.See ªOverheated Engine Protection Operating
Modeº in the Index for information on driving
to a safe place in an emergency.
If No Steam Is Coming From Your
Engine
If you get an engine overheat warning but see or hear
no steam, the problem may not be too serious.
Sometimes the engine can get a little too hot when you:
·Climb a long hill on a hot day.
·Stop after high-speed driving.
·Idle for long periods in traffic.
·Tow a trailer. See ªDriving on Gradesº inTowing a
Trailer on page 4-31
.
If you get the overheat warning with no sign of steam,
try this for a minute or so:
1. In heavy traffic, let the engine idle in NEUTRAL(N)
while stopped. If it is safe to do so, pull off the road,
shift to PARK (P) or NEUTRAL(N) and let the
engine idle.
2. Turn on your heater to full hot at the highest fan
speed and open the window as necessary.
5-25

If you no longer have the overheat warning, you can
drive. Just to be safe, drive slower for about 10 minutes.
If the warning doesn't come back on, you can drive
normally.
If the warning continues, and you have not stopped, pull
over, stop, and park your vehicle right away.
If there's still no sign of steam, push down the
accelerator until the engine speed is about twice as fast
as normal idle speed for at least three minutes while
you're parked. If you still have the warning,
turn off the
engine and get everyone out of the vehicleuntil it
cools down.
You may decide not to lift the hood but to get service
help right away.
Cooling System
When you decide it's safe to lift the hood, here's what
you'll see:
A. Radiator Pressure Cap
B. Coolant Recovery Tank
C. Engine Cooling Fan(s)
If the coolant inside the coolant recovery tank is boiling,
don't do anything else until it cools down.
5-26

When the engine is cold,
the coolant level should be
at or above the COLD
FILL mark. If it isn't, you
may have a leak at
the pressure cap or in the
radiator hoses, heater
hoses, radiator, water
pump or somewhere else
in the cooling system.
{CAUTION:
Heater and radiator hoses, and other engine
parts, can be very hot. Don't touch them. If you
do, you can be burned.
Don't run the engine if there is a leak. If you
run the engine, it could lose all coolant. That
could cause an engine ®re, and you could be
burned. Get any leak ®xed before you drive the
vehicle.If there seems to be no leak, start the engine again.
See if the engine cooling fan speed increases when idle
speed is doubled by pushing the accelerator pedal
down. If it doesn't, your vehicle needs service. Turn off
the engine.
Notice:Engine damage from running your engine
without coolant isn't covered by your warranty.
See ªOverheated Engine Protection Operating
Modeº in the Index for information on driving to a
safe place in an emergency.
Notice:When adding coolant, it is important that
you use only DEX-COOLž(silicate-free) coolant.
If coolant other than DEX-COOLžis added to
the system, premature engine, heater core or
radiator corrosion may result. In addition, the engine
coolant will require change sooner Ð at 30,000 miles
(50 000 km) or 24 months, whichever occurs ®rst.
Damage caused by the use of coolant other
than DEX-COOL
žis not covered by your new vehicle
warranty.
If there seems to be no leak, start the engine again.
See if the engine cooling fan speed increases when idle
speed is doubled by pushing the accelerator pedal
down. If it doesn't, your vehicle needs service. Turn off
the engine.
5-27